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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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Old 10 Aug 2012
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XT660Z keeps blowing fuel pump fuse

Help!! So yesterday was great, did just over 900km from Moscow, found a lovely camping spot, slept well and got ready to go again when phut!
Eds wee Yamaha mysteriously died and would not restart :-(
So we checked over a few things but ultimately we found the fuel pump wasnt getting juice as it had blown its fuse.
We replaced said fuse and carried on into some beautiful scenery before pulling in for some petrol, when ed went to leave, cranked over but wouldn't start, wouldnt you know it, the same fuse.
so clearly theres a short somewhere in the system, we've pulled the tank and looked for damaged wires in the loom, but I suspect the ignition barrel is the culprit, this is because
A) the fuse blows when ignition is switched to live
B) Ed's barrel is free to vibrate as only one bolt holds it in place after somebody kindly broke his steering lock :-(
now we can try to get the barrel removed and checked (it's got security shear off bolts on so needs cutting and cold chiselling)
but I got Ed this far by basically bridging the fuseway with wire (we tried the double amperage fuse 20 instead of 10 and it also blew) clearly its not perfect but
realistically when is this arrangement going to set fire to his bum? We may be parting company in the morning and if he heads all the way from here towards the schengen countries should he try to sort in Moscow, I did the bridging thing partly because there was no alternative and also I figured if the short was intermittent the wire would never get so excited for long enough to overheat but im not a competent auto electrician
Can we just wire the fuel pump directly to the battery with an inline switch and continue?
what would have enough amperage in the ignition barrel to blow the 20 amp fuse if thats the highest fuse rating in the fusebox?
please share these questions and post with anyone who might be able to offer some help! basically Ed needs to decide if its the end of his trip (new ignition set is £1200 from Yamaha + shipping + import duty +accomodations during shipping and clearance so not an option) by the end of the night
thanks in advance
Matt
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Old 10 Aug 2012
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Can you not directly wire the pump to the battery (using a fuse) and switch? at least to rule out ignition.

Mezo.
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Old 10 Aug 2012
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Quote:
Originally Posted by Mezo View Post
Can you not directly wire the pump to the battery (using a fuse) and switch? at least to rule out ignition.

Mezo.
current thinking is to do this with an inline fuse, thereby testing the fuel pump and allowing him a get home fix, unfortunately my spade terminals were too large for me to do this today, will try something different tomorrow now we are in a town at least
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Old 11 Aug 2012
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Now sorted, so ed will now head east with me to baikal
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Old 11 Aug 2012
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Originally Posted by stickysidedown View Post
Now sorted, so ed will now head east with me to baikal
A brief report Matt, especially compared with your OP.
Pray tell, for the benefit of others, what the solution is - temporary bodge, or permanent?
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Old 12 Aug 2012
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Originally Posted by Walkabout View Post
A brief report Matt, especially compared with your OP.
Pray tell, for the benefit of others, what the solution is - temporary bodge, or permanent?
Quite. Where was the short?
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